Spirax Sarco EasiHeat HTG User manual

IM-P481-03-US 9/2017 1
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
© Copyright 2017
Printed in USA
IM-P481-03-US September 2017
Spirax EasiHeatTM HTG Heating System
Compact Heat Transfer Solution
Installation and Maintenance Instructions

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2
Copyright © Spirax-Sarco Limited 2017
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to use the
Work(s) solely within the scope of the legitimate operation of the product (or device).
No other right is granted under this licence. In particular and without prejudice to the
generality of the foregoing, the Work(s) may not be used, sold, licensed, transferred,
copied or reproduced in whole or in part or in any manner or form other than as
expressly granted here without the prior written consent of Spirax-Sarco Limited.

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In addition to putting your personnel at risk of death or serious harm, failure
to comply with the instructions, recommendations and guidance set out in this
document may jeopardize your warranty rights. Further, use of the product(s)
otherwise than in accordance with this document will be undertaken entirely at
your own risk. To the fullest extent legally permitted, Spirax Sarco excludes all
responsibility and liability for any and all loss or damage caused in the event that
the practices and procedures detailed in this document have not been followed.
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11)
in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.
Note: This document refers only to the mechanical installation and commissioning
of the Spirax EasiHeatTM HTG packaged heat exchange system unit and should be
used in conjunction with the relevant IMIs for the other system components and
supplementary safety information for all the system components.
Warning
This product is designed and constructed to withstand the forces encountered
during normal use.
Use of the product for any purpose other than its intended use could cause damage
to the product and may cause injury or fatality to personnel.
Before any installation or maintenance procedure, always ensure that all primary
steam and condensate return lines and secondary water lines are isolated.
Ensure any residual internal pressure in the system or connecting pipework is
carefully relieved.
Allow hot parts to cool before commencing work, to avoid the risk of burns.
Always wear appropriate safety clothing before carrying out any installation or
maintenance work.
Lifting
The Spirax EasiHeat™unit should be lifted by a suitable forklift truck, from the base,
placed in position and securely bolted to the floor.
Warning:
On no account is the Spirax EasiHeatTM unit to be lifted by any other part, other than
the base.
Note: Sufficient space should be provided around the systems location to allow
access for maintenance.
1. Safety information

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Safe operation of these products can only be guaranteed if they are properly
installed, commissioned, used and maintained by qualified personnel (see
Section 1.11) in compliance with the operating instructions. General installation
and safety instructions for pipeline and plant construction, as well as the
proper use of tools and safety equipment must also be complied with.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and
Technical Information Sheet, check that the product is suitable for the
intended use / application.
i) The product has been specifically designed for use on steam, air or
water/condensate. The products’ use on other fluids may be possible
but, if this is contemplated, Spirax Sarco should be contacted to confirm
the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum
and minimum values. If the maximum operating limits of the product are
lower than those of the system in which it is being fitted, or if malfunction
of the product could result in a dangerous overpressure or overtemperature
occurrence, ensure a safety device is included in the system to prevent
such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses
that may be induced by any system to which they are fitted. It is the
responsibility of the installer to consider these stresses and take adequate
precautions to minimize them.
v) Remove protection covers from all connections and protective film from
all name-plates, where appropriate, before installation on steam or other
high temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably
guarded) before attempting to work on the product. Arrange suitable lifting
gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is
required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at
some previous time. Consider: flammable materials, substances hazardous
to health, extremes of temperature.

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1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous
gases, extremes of temperature, hot surfaces, fire hazard (e.g. during welding),
excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any
proposed action (e.g. closing isolation valves, electrical isolation) put any
other part of the system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and
off in a gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric
pressure. Consider double isolation (double block and bleed) and the locking
or labeling of closed valves. Do not assume that the system has depressurized
even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalize after isolation to avoid the danger
of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective
clothing to protect against the hazards of, for example, chemicals, high / low
temperature, radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent
person. Installation and operating personnel should be trained in the correct
use of the product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied
with. Where there is no such system, it is recommended that a responsible
person should know what work is going on and, where necessary, arrange
to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and / or heavy products may present a risk of
injury. Lifting, pushing, pulling, carrying or supporting a load by bodily
force can cause injury particularly to the back. You are advised to assess
the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending
on the circumstances of the work being done.
Please note that if lifting straps are required we would recommend that
they be fitted around the baffle plate legs to prevent damage to the unit.

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2.1 General information
The Spirax EasiHeat™HTG (Heating) incorporating S.I.M.S technology is a complete,
compact and ready-to-use steam to water heat transfer solution that delivers superior energy
efficient performance. It has been designed for applications with stable load conditions such
as closed circuit heating applications. The Spirax EasiHeat™HTG can help you lower costs,
tackle waste and mitigate your environmental impact by reducing your CO2emissions and
carbon footprint, making a positive change towards a more sustainable future.
The base unit of the Spirax EasiHeat™provides the core of the system, while options (see
Sections 2.2) provide additional features such as: high limit package, stop valve package
and energy monitoring.
The Spirax EasiHeat™HTG unit consists of the following core items
(refer to Figure 1):
A Plate heat exchanger.
B Pneumatic or electrically actuated control valve and positioner.
C PLC controller.
D Pipeline ancillaries.
2. General product information
Fig. 1 Spirax EasiHeat™HTG compact heat transfer solution
A
B
D
C
Notes:
1. For additional information about any particular product used in the construction of this
unit see the relevant product specic Technical Information (TI) sheet.
2. For further technical information regarding the Spirax EasiHeatTM HTG see the
Technical Information sheet TI-P481-01-US.

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2.2 Spirax EasiHeat™ HTG nomenclature
The product nomenclature is a reection of the core items and unit options that have been
ordered and supplied – See the table below:
Spirax EasiHeat™HTG nomenclature example:
EHHCC 2 L A EL4 -HL BV1 G1 W - T6 ER2 C1 O1
Spirax EasiHeat™Heating Condensate Control nomenclature
Compulsory
Selection
Building Heating
Unit EHHCC = Spirax EasiHeat™ Heat- ing Condensate Control EHHCC
Control valve size
1 = ½"
2 = ¾" 2
3 = 1"
Pressure vessel
code A = ASME A
Actuation EL4 = Electric (SIMS)
PN = Pneumatic EL4
High limit HL = High limit (SIMS)
IHL = High limit (SX90) HL
Mechanical
Options
High limit actuation
EL only B = Battery back-up B
Manual isolation
valve
V1 = Ball valve V1
V2 = Gate valve
Gasket material G1 = EPDM G1
Extras W = Wheels W
Panel
Options
Panel type
T6=110V UL SIMS
touch screen
P2=110V UL process
controller T6
Energy monitoring E = With energy monitoring E
Remote access
R1=Level 1 - SMS text and
e-mail
R2 = Level 2 - 3G web access R2
R3=Level 3 - both of the above
(R1+R2)
Communication
Options
C1 = Modbus RTU
C2 = BACnet MS/TP (RS485)
*C3 = Modbus TCP/IP (Client)
C4=Pronet C2
C5 = CanOPEN
*C6 = BACnet TCP/IP (Client)
C7=Probus RS485
Options
O1 = Selected option 1
O2 = Selected option 2 O1
O3 = Selected option 3
* Note: not available when panel options R2 or R3 selected

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3. Installation
3.1 Steam and condensate connections
It is important that the steam supply (and compressed air if pneumatic actuation is
selected) to the Spirax EasiHeat™HTG unit is supplied as dry and as clean as possible,
in accordance with good steam engineering practice.
It should also be ensured that all connecting pipework is stress free and adequately
supported.
The steam supply should always be maintained at the specified design pressure and
temperature for the unit. The Spirax EasiHeat™HTG must not operate above the maximum
steam pressure and temperature indicated on the name-plate attached to the plate heat
exchanger.
The installation of an appropriately sized safety valve, to protect any lower pressured
equipment on either the hot or cold side of the plate heat exchanger, is strongly
recommended.
Spirax Sarco supplies a range of traps, strainers, separators, safety valves and pressure
reducing equipment.
3.2 Air supply
If a pneumatic control system is installed, connect a compressed air supply (4.5 to 8 bar g
(65 to 116 psi g)) to the pressure regulator mounted on the control valve.
3.3 Electrical supply
All electrical wiring and connections should be carried out in accordance with National
Regulations.
A lockable isolator / switch disconnect should be fitted adjacent to the unit.
Mains supply is directly connected to the primary side of the incoming control panel isolator
(shown with the IP2X cover removed) and main ground terminal as shown in Figure 2.
Fig. 2
Phase connection Neutral connection Ground connection
Q1
16A
PE
3L2 5L21L2
4T2 6T32T1

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3.4 Electrical specifications
Electrical supply: Refer to the name-plate on the unit
Control panel supply voltage 110 Vac / 60 Hz
240 Vac / 50 Hz
Control panel load requirements Internally fused at 5 amps
Electrical control actuator 24 Vac
4 - 20 mA control
Pneumatic control actuator -
4 - 20 mA control
High Limit isolation valve (optional) 24 Vac
Steam flowmeter TVA (optional) 4 - 20 mA control
PT100 temperature sensors 3 wire
Note: Power supply 10 - 16 A
3.5 Electrical connections
The following are available for customer connection to the Spirax EasiHeat™system if required:
Volt free contacts
Terminal designation Description Type
X14 Enabled / running signal 1 x N/O contact
1 x N/C contact
X15 High Limit alarm 1 x N/O contact
1 x N/C contact
X16 Band Alarm 1 x N/O contact
1 x N/C contact
Fig. 3 VOLT FREE
ENABLE
SIGNAL
K1
/ 7.2
ENABLE
REL AY
21
K2
/ 7.3
HIGH
LIMIT
REL AY
K3
/ 7.4
BAND
REL AY
24 22
21 3 21 3 21 3
131
132
133
141
142
143
151
152
153
21
24 22
11
14 12
VOLT FREE
HIGH LIMIT
ALARM
VOLT FREE
BAND ALARM
X15 X16X14

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Remote operation and retransmission connections
Terminal designation Description Type
X7 Remote set point 4-20 mA input
X17 Remote enable 24 Vdc signal
X9 Retransmission value 4-20 mA output
Fig. 4
CHANNEL 13
4-20 mA
REMOTE PID
LOOP
SETPOINT
X7 21 3 21 3 21 3
001+ 001-
X17 X9
24.3
162
REMOTE SYSTEM
ENABLE
CHANNEL 0
RETRANSMISSION
OF PV OR VALVE
POSITION

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Terminal layout overview
Terminal layout detailed
Note: for detailed wiring schematic options please refer to the 'Operations manual'.
1. Basic
2. Independent high limit
3. Independent high limit with safety
4. American standard
X1 -Water temperature IN
X2 -Water temperature OUT
X3 -Make up water
X4 -Return water
X5 -High limit temperature
Group X6 to X10A
X6 -Linear actuator feedback
X7 -Remote PID loop set point
X8 -Steam meter
X9 -Retransmission value
X10A -Linear actuator control position
Group X10B to X13C
X10B -Linear actuator closed signal
X10C -Linear actuator supply voltage
(Linear actuator A - Electric
actuator only)
X10D -Linear actuator B supply
X10F -Positioner A DC supply
X10G -Positioner B DC supply
X11 -Bypass pump
X12 -Bypass valve
X13 -High limit valve
X13A -High limit valve control output
signal
X13B -High limit valve supply voltage
(electric actuator only)
X13C -High limit valve battery signal
Group X14 to X17
X14 -Volt free signal for enabled
X15 -Volt free high limit
X16 -Volt free band alarm
X17 -Remote enable signal
Fig. 5
X1 - X5
PT100
inputs
X6 - X8
4 - 20 mA
inputs
X9 - X10A
4 - 20 mA
outputs
X10B - X10G
actuator
signals
X11
Bypass
pump
X14 - X16
volt free
signals
X17
remote
enable
X12
Bypass
valve
X13A-C
High limit
valve

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4. Commissioning
We recommend that you use the service and support of a Spirax Sarco commissioning
engineer. Details of this service can be found by contacting Spirax Sarco.
Note: Pre commissioning requirements:
- In most new installations, dirt collects in the steam pipeline during construction of the
system. It is essential to flush this out prior to commissioning.
- Ensure the secondary (cold side) of the system is charged and all air is bled from the
system.
- Ensure that all main isolation valves for both steam and water are isolated.
- Ensure that the electrical supply to the Spirax EasiHeat™is isolated.
- Double check that all steam, condensate and water connections are correctly connected
to the Spirax EasiHeat™.
- Check all flange bolts are tight.
4.1 Mechanical commissioning procedure:
-Check that all the electrical connections are secure and as per the wiring diagram
(Section 3.3, Figure 2).
- Dry commissioning valve stroke check - An initial valve stroke check should be carried
out to ensure free movement of the valve stem.
1. For the electric actuated control
valve, use the manual override on
top of the actuator to raise and lower
the actuator spindle between the two
travel indicators located on the side
of the pillar (Figure 6).
Fig. 6
Handwheel
Travel
indicator
Travel
indicator
Air inlet
Fig. 7
2. For the pneumatic actuated control
valve, remove the existing air supply
and connect an independent air
supply to the actuator (pressure not
to exceed 6 bar g (87 psi g)), allow
the valve to fully open, remove the air
supply from the actuator allowing the
valve to close. Reconnect the original
pipework (Figure 7).

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- Open the secondary (cold side) isolating valves downstream of the Spirax EasiHeat™.
- Start the main secondary water circulating pump(s) if fitted.
- Check and confirm there is secondary water circulation through the Spirax EasiHeat™.
- If the circulation is okay, switch on the main power to the control panel (local isolator).
- Turn the control panel isolation switch to 'ON'.
- Follow the quick start-up guide (WHERE) before opening the steam isolations valves.
4.2 TVA quick commissioning:
The TVA flowmeter is factory set to display data in metric units (changeable to imperial if
required by following the flow chart, Figure 10, or the individual product Installation and
Maintenance Instructions (IMI)).
All commissioning of the TVA is through the arrow buttons located on the front display
see Figure 8.
Fig. 8
Fig. 9
ENtER
PASS 7452
Followed by:
LCD display
5 button keypad
3 screws
Press and hold down the 'OK' button and hold for 3 seconds, then enter the default pass
code.
Use the up and down arrows to set the number then press OK to confirm your selection,
repeat until all numbers are entered.

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(test
display) VER x.x ENTER
PASS xxxx
Temp. °C
Power
Flow
Pressure
kg /h or lb /h
bar g or psi g, depending if
metric or imperial units are
selected.
°C or °F
BASIC
DATA
kW or kBtu /h
Default = 7452
but user
settable.
Conguration
sub-menus
Total
high
Total
low
(Shows the total high 5 digits
for 10 s, then the low 5 digits.
In Kg or lb, kWh or kBTU)
Normal run mode
display sequence
POWER
OUT
NO
SIGNL
SENSR
CONST
HIGH
FLOW
The 4-20 mA
alarm can also
be activated
Shows when ow i / p
exceeds MAX A
No signal
from sensor
The 4-20 mA alarm
can also be activated
Power
interrupted
Flow above
maximum
Signal from
sensor
constant
Error Messages
These alternate with the normal run mode display.
They will be prioritized and will be latched when
they occur.
Pressing the 'OK' button will cancel the displayed
alarm and allow the next one to be viewed.
A continuous alarm will re-occur on the display 2
seconds after it has been canceled.
Power on sequence;
turn on all segments,
then show the software
version no.
OUT
PUTS
METER
4-20 mA
CHECK
4 mA
CHECK
20 mA
SET 4 mA
SOURCE
SET.20 mA
Connect a DVM
and use the up
and down keys
to set 4 or 20 mA
in kg /h or lb /h,
kW or Btu /h.
FLOW
POWER
OP = 4 mA
xxxxx
xxxxx
OP = 20 mA
Fig. 10 TVA configuration displays
To navigate around the first level menu use the up and down arrows, to enter any sub menu
use the right arrow.
4.2.1 TVA flowmeter commissioning chart

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From the Basic DATA menu navigate to OUTPUTS and press the right arrow to enter the
sub menu of 4 - 20 mA.
OUT
PUTS
4-20 mA
PULSE
Fig. 11
CHECK
4 mA
CHECK
20 mA
SET 4 mA
SOURCE
SET.20 mA
FLOW
POWER
OP = 4 mA
xxxx
xxxx
OP = 20 mA
xxx
Fig. 12
OUT
PUTS
After this data has been input, continually press the left arrow button to take you back to
the run mode.
This completes the basic requirement for scaling of the TVA flowmeter suitable for integration
with the HMI.
The next menu Sorce will need FLOW to be selected.
Obtain the correct flow data from the Spirax EasiHeat™specification sheet supplied for
accuracy, thereafter navigate down the menu and input: -
Minimum flow = 4 mA
Maximum flow = 20 mA

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4.3 HMI quick start commissioning procedure:
The HMI display is a 7" touch screen, and the following procedures detail a basic set-up
of the control system from initial power up. A more detailed description of each individual
feature can be found in the full operation and maintenance manual.
Fig. 13
When ready the above screen will appear - touch the screen. If the unit has not already
been configured the following page will appear:
To be able to move to next page the unlock code is essential, after entering the correct
unlock code, the lock icon and the continue button will appear which will transfer you to
the time /date setting page - See Figure 15.
Fig. 14

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Fig. 16
Fig. 18
After unlocking the system (by using the unlock code) and setting the time and date or
if the unit has been returned to factory default one of the following four pages will appear
(pre-configured for designated region):
By choosing the relevant flag for your Country the common default engineering units and
language will automatically be selected for that region. These values can be changed after
the initial commissioning set-up procedure has been completed (see page 33).
The system will advance automatically to allow the selection of the relevant Spirax EasiHeat™
unit - The type of Spirax EasiHeat™unit that is available is dependent on the flag selection.
Fig. 15
Fig. 17
Fig. 19

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The next screen (Figure 20) requires confirmation of the system to be configured:
Fig. 20
Based on the selection of a HTG system the selection will be confirmed by the icon becoming
highlighted with a blue surround and a continue button will appear.
Press the continue button to advance to the system configuration menu.

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The system configuration is now required to be entered on this page; again a selection is
highlighted by a blue surround around the icon.
The system configuration should match the mechanical configuration of the Spirax
EasiHeat™and control system of the plant, correct configuration will show or hide options
that are available after configuration. Some of the screens may contain additional options
which with specified configuration may be hidden; all the options are described in this
document.
Spirax EasiHeat™mechanical and control system configuration options are detailed below
and page 20:
Fig. 21
Not
installed
PLC
controlled
Independently
controlled
BVA PSA Valpes
Fig. 22 High-limit selection
Fig. 23 ¼ turn actuator selection

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Spirax EasiHeat™mechanical and control system configuration options continued:
Local Remote BACnet
Fig. 26 Enable control selection
No position
feedback
Position
feedback
Fig. 25 Linear actuator control signals
Electrical Pneumatic
Fig. 24 Linear actuator selection
Local OWC
Fig. 27 PID set point
(Outside weather compensation)
Not
installed
Installed
Fig. 28 TVA flowmeter selection
Disabled Enabled
Fig. 29 Cost calculation